Applicator brushes and method for using same

ABSTRACT

There is provided an applicator brush that has bristles (filaments) made from a polymeric material derived from plants. Such bristles can provide improved mechanical and aesthetic characteristics compared to conventional bristles made from petrochemical-based synthetics. Bristles made from plant-based polymeric material are also more biodegradable compared to petrochemical-based synthetics. Preferably, the polymeric material is a polylactide polymer.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The present invention relates generally to brushes andapplicators. More particularly, the present invention relates tobristles, fibers and filaments that can be used in brushes and/orapplicators, especially for cosmetic use. In particular, the bristles,fibers and filaments are made of polylactide polymer or polymer resinthat, in turn, is derived from natural, renewable sources, such asplants.

[0003] 2. Description of the Prior Art

[0004] Applicator brushes are used to apply a variety of materials, suchas, for example, hair dyes, medicaments, paints, toothpastes andcosmetic eyeliner, eyeshadow, mascara, nail polish, powder, and rouge.

[0005] The broad purpose of an applicator brush is to pick up anadequate supply of a material from a container, carry it from thecontainer to an application site, and apply the material uniformly andeasily to the application site. More particularly, the applicator brushmust meet several mechanical and aesthetic requirements. First, theapplicator brush should have a certain stiffness or resiliency, yet havesmooth feedback. Second, the applicator brush should have an affinityfor the composition it is being used to apply, yet withstandcontaminants, such as skin oils and environmental odors. Third, theapplicator brush should have high wear resistance, ultraviolet lightstability, elastic recovery, twist retention, and a pleasant, soft feel.For cosmetic brush applicators that are used for application ofcosmetics, the pleasant, soft feel should include a silky and soft feelto the user's body.

[0006] Of course, the importance of these mechanical and aestheticrequirements will vary depending upon the intended use of the applicatorbrush. Along these lines, bristles, fibers and filaments have beendeveloped with variations in characteristics, such as, for example,density, cross-section, number of twists, slip characteristics, wicking,shape, and core size. The variations in characteristics primarily dependon the intended use of the brush.

[0007] Typically, conventional applicator brush bristles are made fromnylon, polyester, polyether-block amides, and/orpolytetraflouroethylene. Brush bristles made from these materials mayhave an acceptable degree of strength, stability, and wear resistance,however the bristles made with nylon and these other petrochemical-basedsynthetic materials consume a large amount of energy or fuel.Specifically, nylon is made through the energy intense processes fromhydrocarbon petroleum fuel stock. The source of supply of this stock canbe limited and unpredictable, and the processes are expensive. Moreover,nylon and these other petrochemical-based synthetics biodegradeextremely slowly, if at all.

[0008] Thus, there is a need for applicators with bristles, fibers, andfilaments (hereinafter collectively referred to as “bristles”) thatprovide the same or improved mechanical and aesthetic properties, namelyare formable into a broad range of bristle densities, cross-section andcross-sectional dimensions, various number of twists, unique shapes, andcore types (e.g., hollow, solid, or filled) and have the desired slipand wick characteristics, yet have a source of material that isreliable, less expensive to make, and biodegradable. The bristles of thepresent invention achieve all of the above, and they are believed to bemuch less expensive since thirty to fifty percent less fossil fuel isused to produce these bristles versus the above noted conventionalbristles.

[0009] The above need is achieved by the present invention that uses apolylactide polymer or polymer resin as the bristles for an applicatorbrush.

[0010] U.S. Pat. Nos. 5,525,706, 5,807,973, 5,922,832, 6,005,068,6,093,791, and 6,111,060 are assigned on their faces to Cargill, Inc.and describe uses of polylactide polymer for films, foams, and nonwovenfabrics. In addition, polylactide polymers have been used in diapers,disposable razor handles, hospital gowns, personal hygiene articles,surgical drapes, and sanitary napkins, as well as for use in carpet,clothing, packaging for food and cosmetics, plastic film for candywrappers, and window envelopes.

SUMMARY OF THE INVENTION

[0011] It is an object of the present invention to provide an applicatorand/or brush that has natural-based bristles made from plant-basedplastics, and a method of making and using such an application and/orbrush.

[0012] It is another object of the present invention to provide such anapplicator and/or brush wherein the plant-based plastic is abiodegradable polylactide polymer or polymer resin made from renewablesources.

[0013] It is still another object of the present invention to providesuch an applicator or brush in which such natural-based bristles can beformed into a broad range of dimensions, sizes, and shape.

[0014] It is still a further object of the present invention to providesuch an applicator and/or brush that is particularly suited for cosmeticuse.

[0015] These and other objects and advantages of the present inventionare provided by an applicator brush that has natural-based bristles madefrom a plant-based polymer, such as polylactide polymer, that is derivedfrom renewable, natural plant sources, such as corn, wheat, and sugarbeets.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016]FIG. 1 is a preferred embodiment of a mascara applicator brushaccording to the present invention;

[0017]FIG. 2 is an embodiment of a nail lacquer brush according to thepresent invention;

[0018]FIG. 3 is an embodiment of a flat blush brush according to thepresent invention;

[0019]FIG. 4 is an embodiment of a blush/makeup brush according to thepresent invention;

[0020]FIG. 5 is an embodiment of an eyeliner brush according to thepresent invention;

[0021]FIG. 6 is an embodiment of a toothbrush according to the presentinvention; and

[0022]FIG. 7 is an embodiment of a hair brush according to the presentinvention.

DETAILED DESCRIPTION OF THE INVENTION

[0023] Referring to FIG. 1, there is provided a preferred embodiment ofthe present invention, namely a mascara applicator or brush generallyrepresented by reference numeral 1. As used hereinafter, “applicator”shall include an applicator and/or a brush. Also, the present inventionincludes all types of applicators that are used to apply liquids,gel-type and/or semi-solid materials onto any substrate. For example,the applicator of the present invention can be a hair brush, a hair dyebrush, a medicament brush, a paintbrush, and a toothbrush. Perhaps moreimportantly, applicator 1 can be used as a cosmetic applicator brush toapply a variety of cosmetics, such as eyeliner, eyeshadow, lipstick, lipgloss, mascara, nail polish and/or lacquer, blush and/or makeup, powder,rouge, and nail cosmetics, such as polishes and enamels, to a human.

[0024] Again referring to FIG. 1, applicator 1 has a handle 16 and abristle portion 20. When applicator 1 is adapted for use in applyingcosmetic compositions, such as mascara, it is preferred that handle 16has a rod 14 extending therefrom and secured to, or part of, a core 12.Handle 16 is adapted to act as a cap for a cosmetic or mascaracontainer, while rod 14 is adapted to fit within the neck of thecontainer. Core 12 is adapted to receive a plurality of bristles 30.Core 12 is preferably a twisted metallic wire. Bristles 30 arepreferably crimped within twisted core 12 and, thereby, flare outwardfrom the core in a multidirectional, radial pattern, which gives theeffect of a uniform distribution of bristles 30. Alternatively, bristles30 may be made to resist crimping, thereby forming a helical array abouttwisted core 12.

[0025] Handle 16 may be made using any material known to the art andsuitable for the particular use thereof. Preferably, handle 16 is madeof a thermoplastic material, more preferably a plant-based polymer, suchas the polylactide polymer discussed below, so that the applicator brush1 may be completely biodegradable.

[0026] Bristle portion 20 has one or more bristles 30. The bristles 30are made from a natural, plant-based polymer. Such plant-based polymersinclude the following polymers or polymer resins: polylactide (PLA),polycaprolactone (PCL), polyhydroxybutyrate/valerate (PHB/V),polyglycolic acid (PGA), and polymers based on starch or starchderivatives. Bristles formed by copolymerizing and/or coextrudingplant-based polymers with materials presently used to form conventionalbristles are also included within the scope of the present invention.

[0027] Preferably, bristles 30 are made from polylactide polymer. Thispolymer has the following general structure:

[0028] where n is the average molecular weight from about 10,000 toabout 300,000 and preferably at least 50,000 to 250,000. Preferredpolylactide polymers are produced by Cargill Dow. Several kinds ofpolylactide polymers are described in U.S. Pat. Nos. 5,798,435,5,981,694, and 5,998,552, which are incorporated herein by reference.

[0029] The plant-based polymer is made by the processing of naturalrenewable sources, such as corn, wheat, sugar beet, or other plants.

[0030] The plant-based polymer can be processed into bristles byconventional methods. The processing parameters of the plant-basedpolymer can be modified to achieve enhanced performance and properties.The plant-based polymers readily accept dyes, additives and fillers, andcan be processed readily with other materials that may provide furtherenhanced bristle performance, properties and processability.

[0031] A bristle 30 made from a plant-based polymer has increased slipcharacteristics and increased wicking properties, both of which aredesired in an applicator bristle. Also, bristles 30 have been found tohave a silky feel, downgagability (which is the ability to make thinnerfibers), excellent UV stability, strong resistance to grease and oil,high aroma and flavor barrier properties, superior moisture wicking, aswell as superior twist retention, resilience, stiffness, and elasticrecovery. Moreover, the bristles of the present invention are highlyenvironmentally friendly because of their biodegradablility.

[0032] Bristles 30 that are made from plant-based polymers, especiallyPLA polymers, can have any shape depending upon their intended use. Forexample, bristles 30 made from PLA polymer may have one or morecross-sectional portions that are generally flat, circular, square,rectangular, hexagonal, quadrilobal, J-shaped, S-shaped, U-shaped,V-shaped, and/or X-shaped. In cross-sectional view, bristle portion 20may be straight, tapered, threaded, curved, oblong, arrowhead,comb-shaped or any combination thereof. The ends of the bristles may besplit, crimped or straight. In addition, each bristle may have all or aportion that is flared, tapered, grooved, solid, hollow or filled. Ifgrooved, up to five (5) capillary channels may be formed along at leasta portion of the length of the bristle surface, with each channel havinga depth and width in the range from 0.01 to 0.06 millimeters. Further,bristle 30 may have any number of turns or twists, a broad range ofbristle densities, and a large range of cross-sectional dimensions. Thebristle may be natural, dyed or pigmented.

[0033] For example, the concentration or density of bristles 30 inbristle portion 20 is preferably from about 10 to about 65 bristles perhelical turn of core 12, especially when applicator brush 1 is a mascaraapplicator brush. More preferably, the bristle density is from about 40to about 60 bristles per helical turn of core 12. Most preferably, thebristle density is from about 45 to about 55 bristles per helical turnof core 12. This concentration provides an even application of mascarawithout forming lumps of mascara on the eyelashes or on bristle portion20. Also, the diameter of each bristle 30 is preferably about 0.01 toabout 0.40 mm, more preferably about 0.06 to about 0.25 millimeters.

[0034] The bristles of the present invention offer a general improvementover nylon and other petrochemical-based bristles. For example, theyappear to have superior twist retention, better fold, and better elasticrecovery than petrochemical-based bristles. Also, the bristles of thepresent invention retain the desired stiffness and resiliency, yet havea silky, soft feel.

[0035] By way of example, additional embodiments of the presentinvention are shown in FIGS. 2 to 7. FIG. 2 depicts a nail lacquerbrush. FIG. 3 depicts a flat blush brush. FIG. 4 depicts a blush/makeupbrush. FIG. 5 depicts an eyeliner brush. FIG. 6 depicts a tooth brush.FIG. 7 depicts a hair brush.

[0036] The present invention having been thus described with particularreference to a preferred form thereof, it will be obvious that variouschanges and modifications may be made therein without departing from thespirit and scope of the present invention as defined in the appendedclaims.

Wherefore we claim:
 1. An applicator brush comprising one or morebristles made from a naturally based polymeric material.
 2. Theapplicator brush of claim 1, wherein said polymeric material is derivedsubstantially from plants.
 3. The applicator brush of claim 2, whereinsaid polymeric material is selected from the group consisting of:polylactide, polycaprolactone, polyhydroxybutyrate/valerate,polyglycolic acid, polymers based on starch or starch derivatives, andany combinations thereof.
 4. An applicator brush comprising one or morebristles made from a polylactide polymer.
 5. The applicator brush ofclaim 4, wherein said polylactide polymer is derived substantially fromone or more plants.
 6. The applicator brush of claim 4, wherein saidpolylactide polymer has the following general structure:

where n is the average molecular weight from about 10,000 to about300,000.
 7. The applicator brush of claim 6, wherein said n is theaverage molecular weight from about 50,000 to about 250,000.
 8. Theapplicator brush of claim 1, wherein said one or more bristles areadapted to apply a cosmetic composition.
 9. The applicator brush ofclaim 8, wherein said cosmetic composition is selected from the groupconsisting essentially of: eyeliner, eyeshadow, lipstick, lip gloss,mascara, nail polish, powder, and rouge.
 10. The applicator brush ofclaim 1, wherein said one or more bristles are adapted to apply amaterial selected from the group consisting essentially of hair dye,medicament, paint, and toothpaste.
 11. The applicator brush of claim 1,further comprising a bristle portion having a plurality of saidbristles, and a handle connected to said bristle portion, wherein saidbristle portion has a longitudinal axis about which said plurality ofbristles are helically turned, and wherein from about 10 to about 65 ofsaid plurality of bristles are disposed about one helical turn.
 12. Theapplicator brush of claim 11, wherein the applicator brush isbiodegradable.
 13. The applicator brush of claim 11, wherein at leastsome of said plurality of bristles are hollow.
 14. The applicator brushof claim 11, wherein at least some of said plurality of bristles have across sectional dimension from about 0.01 to about 0.40 mm.
 15. Theapplicator brush of claim 11, wherein at least one capillary channel isformed on at least a portion of the surface of at least some of saidplurality of bristles.
 16. A method of applying a liquid, gel-type orsemi-solid material to a surface comprising the step of: depositing thematerial on an applicator brush having one or more bristles made of anaturally based polymeric material.
 17. The method of claim 16, whereinsaid polymeric material is derived substantially from plants.
 18. Themethod of claim 16, further comprising applying the material from theapplicator brush onto a person or substrate.
 19. The method of claim 16,wherein said polymeric material is selected from the group consistingof: polylactide, polycaprolactone, polyhydroxybutyrate/valerate,polyglycolic acid, polymers based on starch or starch derivatives, andcombinations thereof.
 20. The method of claim 16, wherein said polymericmaterial is a polylactide polymer.
 21. The method of claim 20, whereinsaid polylactide polymer has the following general structure:

where n is the average molecular weight from about 10,000 to about300,000.